Tailor welded blanks (TWB) are extensively used by the automotive industry due to their positive effects on the total weight of bodywork parts and cost due to the optimised usage of materials. Conventionally, TWB's are produced by the laser beam welding (LBW) process. In the case of Al alloys the results not always fulfil the requirements imposed by the industry mostly because of problems related to the interaction between laser beam and base material. Friction Stir Welding (FSW) offers an attractive alternative to LBW because of the excellent properties (particularly ductility), reproducibility, robustness, and surface finished obtained with the process. However, questions have been raised regarding the productivity of FSW against LBW. In the present study two Al alloys of the 6xxx and 5xxx series with thickness ranging from 1.0mm to 1.5mm have been selected for investigation. Similar and dissimilar welds have been produced with varying thickness combinations. Welding speeds up to 10m/min have been systematically investigated. The welds produced have been subjected to microstructural analysis and mechanical testing. The deformation behaviour of the welded joints has been determined using an optical strain measurement system.
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